KTM 400-660 LC4 1998-2005 User Manual

4-8F
Repair manual KTM LC4 Art.-Nr. 3.206.024 -E
– Pull water pump upward and simultaneously turn crankshaft.
NOTE: When groove
A in the HH bolt is vertical, the water pump can
be pulled upward and taken out of the cylinder head without the
application of force.
Blocking the crankshaft
– Turn the piston to position TDC (mark B must coincide with the
plane surface of the cylinder head).
– Undo the crankshaft locking bolt
1.
– Remove the copper disc
2.
NOTE: Same engines are equipped with a normal bolt M8x16 and a
copper washer 8x12x1 instead of the crankshaft locking bolt M8 and
a copper washer 8x14x3. In this case the special tool
580.30.080.000 must be used.
– Reinsert crankshaft locking bolt by hand.
– If the bolt does not slide smoothly into its bore, slightly move the
camshaft gear (if cylinder head top section is mounted turn the
flywheel) back and forth until the crankshaft locking bolt engages
in its bore.
– Tighten crankshaft locking bolt with 20 Nm.
! CAUTION
!
U
NDER NO CIRCUMSTANCES APPLY FORCE TO BOLT IN CRANKSHAFT LOCKING BOLT
AS THIS WILL DAMAGE THE CRANKSHAFT
.
Removing the camshaft and the automatic tensioner
– Remove the driving bolt 3 together with the two washers.
– Remove the two bolt
4 and take off the automatic tensioner 5 and
the clamp
6.
A
B
1
2
3
4
5
6

KTM 400-660 LC4 1998-2005 Specifications

General

Brand	KTM
Model	400-660 LC4 1998-2005
Category	Engine
Language	English

Summary

REMOVING AND REFITTING ENGINE

REMOVING THE ENGINE

Detailed steps for safely removing the engine from the motorcycle frame.

REFITTING THE ENGINE

Detailed steps for correctly reinstalling the engine into the motorcycle frame.

DISASSEMBLING THE ENGINE

REMOVING THE CYLINDER HEAD

Steps for removing the cylinder head assembly from the engine.

PARTING OF ENGINE HOUSING

Instructions for separating the engine crankcase halves.

SERVICING ON INDIVIDUAL COMPONENTS

WORKING ON THE RIGHT HOUSING HALF

CRANKSHAFT

Technical specifications and checks for the crankshaft.

CHECKING THE PISTON

DISASSEMBLING THE CAMSHAFT AND CHECKING THE COMPONENTS FOR WEAR

Steps to disassemble the camshaft and inspect its components for wear.

ASSEMBLING THE ENGINE

ASSEMBLY OF ENGINE HOUSING

MOUNTING THE CLUTCH

MOUNTING THE CYLINDER HEAD

ELECTRICAL

ELECTRIC STARTER SYSTEM

IGNITION SYSTEM

FUEL SYSTEM

MIKUNI BST 40

DELL’ORTO

KEIHIN FCR 41

TROUBLE SHOOTING

TROUBLE SHOOTING (SX, SXC, SC, SMC)

Common issues and solutions for SX, SXC, SC, and SMC models.

TROUBLE SHOOTING (LC4 COMPETITION)

Common issues and solutions for LC4 Competition models.

TROUBLE SHOOTING (LC4)

Common issues and solutions for LC4 models.

CHASSIS

DISMOUNTING/MOUNTING THE CHASSIS COMPONENTS

OVERHAULING THE CHASSIS COMPONENTS

REPLACING THE FRONT WHEEL BEARINGS

REPLACING THE REAR WHEEL BEARINGS

TIGHTENING TORQUE

ENGINE

Specific torque values for engine assembly bolts and nuts.

CHASSIS

Specific torque values for chassis assembly bolts and nuts.

PERIODIC MAINTENANCE SCHEDULE

VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC

Treat electrical contacts and switches with contact spray

WIRING DIAGRAMS

DETAIL WIRING DIAGRAMS

Detailed wiring diagrams for various models and systems.

EXPLANATION OF CONNECTORS, CABLE COLORS